A method of manufacturing fermented Şalgam juice

Abstract

The invention relates to a novel manufacturing method for the production of the Turkish fermented beverage şalgam juice. Specifically, it addresses process optimization to reduce fermentation time, enhance the functional properties of the beverage, eliminate labor-intensive steps, and decrease energy requirements while improving food safety compared to traditional methods. Additionally, the fermented carrot, previously regarded as waste, is now converted into valuable food ingredients or supplements, thereby ensuring a zero-waste production model is achieved.

Description

[0001] DESCRIPTION

[0002] A METHOD OF MANUFACTURING FERMENTED SALGAM JUICE

[0003] Technical Field

[0004] The invention relates to a novel manufacturing method for the production of the Turkish fermented beverage §algam juice. Specifically, it addresses process optimization to reduce fermentation time, enhance the functional properties of the beverage, eliminate labor-intensive steps, and decrease energy requirements while improving food safety compared to traditional methods. Additionally, the fermented carrot, previously regarded as waste, is now converted into valuable food ingredients or supplements, thereby ensuring a zero-waste production model is achieved.

[0005] State of the Art

[0006] Fermented §algam juice is a traditional beverage produced in Tiirkiye, particularly in the ukurova region (Adana, Mersin, Hatay, and Osmaniye). The fermented §algam juice is reddish in color, turbid, salty and sourish, drink based on lactic acid fermentation. Although its consumption is increasing across all the regions of Tiirkiye and exports to various countries grow each year, beverage production remains highly localized, with many businesses adhering to conventional production methods. Despite numerous academic studies and articles on fermented §algam juice production and methods for improving its properties, none have been implemented at an industrial scale. Furthermore, no documented industrial production method exists in the literature for enhancing fermented §algam juice production. Although, some studies have explored the use of starter cultures in §algam fermentation, without applying the production steps that are the subject of the present invention, methods provided in the literature alone are not sufficient for industrial scale production

[0007] Fermented §algam juice mainly made by fermenting black or purple carrot (Daucus Carota ssp. Sativus var. Atrorubens Alef) is a functional beverage known for its rich nutritional profile, immune-boosting properties, and various health benefits [1], The anthocyanin pigments found in black carrots, which are the primary ingredient in fermented §algam juice production, contribute to its distinctive red-purple color and offer potent antioxidant properties that may reduce the risk of chronic diseases [1], Additionally, fermented §algam juice contains vitamins A, B, and C, as well as essential minerals such as calcium, potassium, magnesium, and iron, which contribute to bone health and support digestive and liver functions [2],Existing industrial fermented §algam juice production is mainly based on uncontrolled fermentation that relies on natural microflora. The two main methods used in the industry are the Traditional Method and the Direct Method. Both lack standardized microbial control, which causes variations in product quality [3],

[0008] In the Traditional Method, there are two fermentation stages called dough fermentation and carrot fermentation. During dough fermentation, a mixture of bulgur flour, salt, and yeast or sourdough is prepared and left to ferment at room temperature for 3 to 5 days. In this period, lactic acid bacteria and yeast produce acid and create a sourdough. In the carrot fermentation stage, the fermented dough is either transferred directly into a fermentation tank or filtered to extract its liquid. Black or purple carrots are manually inspected, trimmed, washed, and sliced. Then they are added to the tank together with salt, water, and optionally turnip. This mixture undergoes a second fermentation for 7 to 10 days at room temperature in small-scale production. However, in industrial production, fermentation at least 4 weeks, commonly longer. Because the microbial environment is uncontrolled, there are often variations in taste, aroma, and microbiological quality. To reduce these inconsistencies, some producers add up to 15% of previously fermented §algam juice as inoculant, but this does not guarantee full standardization [3].

[0009] The Direct Method simplifies the traditional two-stage fermentation by combining all ingredients, chopped black or purple carrots, bulgur flour, salt, yeast, water, and optionally turnip, into the fermentation tank. Lactic acid bacteria dominate the process, but because fermentation is uncontrolled, other microorganisms including yeasts and possible pathogens can grow, which causes quality inconsistencies and food safety risks [3],

[0010] Both methods have several disadvantages. Manual handling of ingredients, especially sorting and preparing the carrots, increases labor costs. Fermentation takes at least 4 weeks, which reduces efficiency in large-scale production. Uncontrolled fermentation allows the growth of undesirable microorganisms at early stages, which increases contamination risk and often requires corrective measures like additives to ensure uniformity. The lack of standardized microbial populations results in inconsistent taste, aroma, and functional properties, leading to variation between batches.

[0011] Another approach used by some producers is back-slopping, in which a portion of previously fermented §algam juice is used to inoculate new batches [4], This method helps adapted microbial strains become dominant over time, similar to a natural starter culture. However, inindustrial settings, it has limited effectiveness due to microbial drift, contamination, and inconsistency between batches [5],

[0012] A more refined approach in the literature involves the use of starter cultures in the fermentation process [6], This increases food safety by limiting uncontrolled microbial growth. However, it does not solve problems related to labor-intensive processing, long fermentation periods, or the lack of standardization.

[0013] Although these methods dominate existing production practices, several patents have explored alternative techniques to overcome issues like microbial control and product variability. For example, US 2021 / 0289820A1 discloses preparations of low or non-alcoholic beverages of plant origins, and more particularly preparations of vegetable juices. Also relates to the use of microorganisms to prepare such beverages. WO 2024068429A1 field of coffee fermentation. In particular, the invention relates to methods of coffee fermentation with microorganisms and coffee products obtained therefrom.

[0014] The production of industrial fermented §algam juices has traditionally been carried out using methods that rely on uncontrolled fermentation processes driven by natural microorganism populations. These conventional processes have several drawbacks that prevent the full potential of fermented §algam juice, in terms of both its nutritional value and health benefits, from being realized. The primary challenges in traditional production methods include inconsistent product quality, contamination by undesirable microorganisms, labor-intensive processes, high energy and facility space requirements, and prolonged fermentation times. Existing industrial fermented §algam juice production systems predominantly involve manual operations for many subprocesses. This reliance on manual labor increases the complexity and labor intensity of large-scale production. For example, traditional methods involve several labor-intensive steps, such as carrot selection, edge chopping, slicing, filling carrot bags, placing them in fermentation vessels, preparing sourdough, adding sourdough to fermentation vessels, removing the carrots post-fermentation, and handling fermentation residue carrots. These labor-intensive procedures not only raise labor costs but also reduce overall efficiency and compromise food safety. Despite these challenges, no solutions to this problem have been identified in the existing literature. As the demand for fermented §algam juice increases, the industry urgently requires novel approaches to streamline the production process.

[0015] In current industrial fermented §algam juice production, fermentation is carried out solely by the natural microflora. However, the black / purple carrots used in fermented §algam juiceproduction may harbor harmful microorganisms, which could pose safety risks to consumers. Additionally, the microflora present in the fermentation medium can contain microorganisms that negatively impact the sensory properties of the final product. To mitigate these risks, current industrial practices involve adding high salt concentrations (greater than 1.5%) to the fermentation medium. Although this approach partially addresses food safety concerns, the natural microorganism populations and their structure vary from batch to batch, resulting in inconsistent fermentation kinetics. As a result, parameters such as taste, smell, acidity, acid profile, and pH can differ significantly between batches. Although this problem is well-documented in the literature, a comprehensive solution has not been developed.

[0016] After fermentation, traditional methods require manual removal of the carrots from the tank, as they are typically sliced for fermentation. This results in spent fermented black / purple carrots that is often discarded due to their high salt content. Only a small portion of the fermentation residue is utilized as an animal feed additive, while the remainder is waste, contributing to environmental pollution and soil degradation due to its acidity and salt content. The current methods for processing and utilizing this fermentation residue are costly and limited. Although there are not any published documents about how much fermentation residue is produced, on average, 20% of black / purple carrots use industrial fermented §algam juice, and approximately 200 million liters of fermented §algam juice is produced every year in Tiirkiye. One can roughly predict that 50 million kilograms of waste fermentation residue is produced by fermented §algam juice production.

[0017] Also, traditional methods of fermented §algam juice production often result in significant variations in taste, smell, and acidity due to temperature fluctuations during the long fermentation process. Even with the introduction of starter cultures, the microbial community in the fermentation vessel is influenced by these temperature changes, leading to inconsistent product characteristics.

[0018] Current industrial fermented §algam juice production requires fermentation periods of four weeks or more, depending on climatic conditions. Large-scale industrial production typically occurs in fermentation tanks with capacities ranging from 5 to 10 tons for larger businesses and 100 to 250 liters for smaller businesses. Although smaller batch sizes are easier to manage, handling large fermentation vessels during extended fermentation times presents significant challenges. Tanks with a capacity of 5 to 10 tons are difficult to manage with traditional methods, yet the growing demand for fermented §algam juice necessitates even larger volumes for efficient production. The small tank sizes in current methods necessitate the use of multiplefermentation tanks to meet demand, which increases facility space requirements and results in higher energy consumption for climatizing the fermentation environment. Some fermented §algam juice producers utilize 1000 or more parallel 10-ton tanks to fulfill the demand. Additionally, to handle fermentation with a high number of tanks, more than 300 workers are required.

[0019] Brief Description of the Invention

[0020] The aim of the present invention is to develop an efficient and automated method for producing fermented §algam juice that reduces labor-intensive processes, minimizes energy requirements, decreases waste, and ensures standardized taste across every batch. Unlike traditional and previously studied production methods, the invention introduces a novel, standardized, and efficient approach that addresses longstanding inefficiencies, labor-intensive steps, and food safety concerns while delivering consistent product quality and scalability. With the present invention, the same production volume can be achieved with much fewer tanks due to reduced fermentation time and increased fermentation volume.

[0021] According to the invention, all ingredients are crushed or mixed with water, enabling their transfer via pumps and pipes in easily cleanable, aseptic, closed piping systems. This eliminates labor-intensive steps after the initial manual inspection and washing of carrots. Once washed, the carrots are crushed, pulverized, shredded, or ground automatically, removing the need for conveyor-based transport and manual handling. Consequently, the process becomes simpler, safer, and more efficient.

[0022] Before or during the filling of ingredients into the fermentation tanks, enzymes can optionally be added to further treat the carrots. This enzymatic treatment enhances nutrient availability, accelerates fermentation, and makes the carrots more suitable for subsequent processing or use after fermentation. It also reduces energy consumption and volume of fermented processed carrots , as most of the carrots are hydrolyzed during fermentation due to enzymatic activity. The method employs starter cultures during both the bulgur flour (or grain / cereal) fermentation stage (often referred to as “dough fermentation”) and the main carrot fermentation stage. Introducing beneficial microorganisms at these early phases ensures they quickly dominate the fermentation environment, effectively preventing contamination and minimizing temperature fluctuations. The result is a significantly shortened fermentation time, completing in approximately 2 to 4 days, which is at least 50% faster than traditional or industrial methods that often take four weeks or longer.The use of enzymes together with crushing, grinding, pulverizing, or shredding the carrots further shortens the fermentation period. By completing fermentation more quickly, manufacturers can produce the same volume of fermented §algam juice with fewer fermentation tanks, thereby reducing initial investment, facility size, and operational costs. The shortened fermentation also reduces energy requirements for climatization and temperature control. In industrial fermented §algam juice production, 15% to 25% carrot content is typically used, depending on the manufacturer’s formulation. However, the extended and uncontrolled nature of traditional four-week fermentation imposes practical limits on carrot ratios. Variations in formulations often lead to significant taste differences or spoilage risks. In contrast, the present invention’s shorter, controlled fermentation allows for higher carrot ratios, paving the way for concentrated fermented §algam juice with lower overall resource consumption and improved process efficiency.

[0023] Traditional industrial fermented §algam juice frequently contains 1.5% or more salt (NaCl) to suppress contamination and pathogens in an uncontrolled microbial environment, leading to a high sodium content in the final product. Large quantities of §algam juice (over 200-300 ml) may thus present health risks for certain individuals, particularly the elderly. In the present invention, however, the immediate introduction of starter cultures and controlled conditions reduce or eliminate the need for high salt concentrations. When necessary, optional ingredients such as arginine or various salt combinations (e.g., NaCl, KC1, CaCL, MgSCL, MgCb, MnSCL, MnCL, MSG, magnesium phosphate, sodium lactate, sodium acetate) can be incorporated to maintain or enhance taste, improve mineral content, and deliver desirable sensory qualities without compromising food safety.

[0024] Every year, roughly 50,000 tons of fermentation residue from carrot processing are discarded, often burned or left to accumulate in soil, posing environmental risks. By combining carrot processing with controlled fermentation, the present invention makes it possible to incorporate fermented processed carrot into a variety of foods, such as soups, chips, food coloring agents, postbiotics, prebiotics, sauces, thickening agents, or dietary supplements. This not only resolves the waste management challenge in traditional fermented §algam juice production but also transforms a costly residue into a valuable byproduct, contributing to economic gains and aligning the process with zero-waste principles.

[0025] The present invention marks a breakthrough in fermented §algam juice production by addressing inefficiencies, high labor requirements, extended fermentation times, food safetyconcerns, and waste disposal challenges. By integrating automation, enzymatic treatment, and controlled fermentation with starter cultures, this method minimizes labor through reduced manual operations and streamlined material handling, shortens fermentation time by at least 50% to lower energy consumption and improve production throughput, ensures food safety through immediate microbial control (thereby reducing or eliminating the need for high salt concentrations or corrective additives), enhances standardization of taste, aroma, and functional properties to maintain consistency between batches, and promotes sustainability by enabling higher carrot usage and repurposing of fermentation residue. Overall, this superior alternative to existing manufacturing methods offers scalability, improved product quality, and significant cost savings, making it ideally suited for modern industrial fermented §algam juice production.

[0026] Figures

[0027] Figure 1 : View of production method flowchart.

[0028] Detailed Description of the Invention

[0029] The invention relates to a novel manufacturing method for the production of the Turkish fermented beverage §algam juice, entire process is carried out in a liquid phase. Specifically, it addresses process optimization to reduce fermentation time, enhance the functional properties of the beverage, eliminate labor-intensive steps, and decrease energy requirements while improving food safety compared to traditional methods. Additionally, the invention includes a method for utilizing the fermentation residue (fermented processed carrot) generated during production, leveraging its unique properties acquired through the proposed manufacturing process. This innovation enables a zero-waste production system for fermented §algam juice. The method begins with the optional preparation of bulgur flour or alternative ground grains / cereals for pre-fermentation. Preferably grains / cereals include but not limited to corn, barley, chickpea, beans, quinoa, rice, lentil, buckwheat, oat, rye, which is mixed with salt-water or water and heat-treated. In one embodiment, the bulgur flour itself may be heat-treated before mixing. A starter culture is added to the mixture, which is then thoroughly mixed. The starter culture preferably contains at least one yeast species and at least one lactic acid bateria species. Preferably, the yeast species include but are not limited to S. cerevisiae, Pichia kluyveri, Pichia fermentans, and Pichia pastoris. Preferably, the lactic acid bacteria species is selected from the group consisting of Lactiplantibacillus plantarum, Lactobacillus brevis, Lacticaseibacillus casei, Lactiplantibacillus pentosus, Pediococcus pentosaceus, Lactobacillus rhamnosus, Lactobacillus acidophilus, Leuconostoc mesenteroides, Weissella cibaria, Weissella confusa,Lactiplantibacillus argentoratensis, Pediococcus acidilactici, Lacticaseibacillus paracasei, Lactobacillus reuteri, Levilactobacillus sakei, Weissella koreensis, Lactococcus lactis, Lactobacillus delbrueckii.

[0030] The fermentation is carried out at a controlled temperature with minimal fluctuations (± 1°C) for a duration of one to two days. Preferably, the bulgur flour and water are heat-treated separately in a manner that ensures, upon combination, the mixture reaches a temperature between 28°C and 37°C. This temperature range is optimal for fermentation, facilitating microbial activity while preventing excessive fluctuations. The liquid fermentation process enables efficient handling, reduces labor requirements, allows for full automation, and makes the method scalable to high production volumes, unlike traditional, solid-state, sourdough fermentation techniques. In one embodiment, bulgur flour or other ground cereals directly included in main processed black / purple carrot fermentation, without any prior fermentation. The next step involves the processing of black or purple carrots, which are selected for quality and then thoroughly washed. The carrots are subjected to mechanical processing through pulverization, shredding, grinding, or crushing. Optionally, at least one enzyme, such as Pectinase, Cellulase, Glycosidase, Hemicellulase, Amylase, Laccase, Naringinase, Protease, or Tannase, may be added to facilitate the breakdown of the carrot fibers. The processed carrots are then combined with salt-water or water, a starter culture containing at least one lactic acid bacteria species and preferably containing at least one yeast species, and the previously optionally fermented cereal flour, after which the mixture is transferred to a fermentation tank. The mixing of these ingredients may occur either before or after the tank is filled. In certain embodiments, arginine may be incorporated into the mixture to enhance the salty and umami flavors of the final product. At least one ingredient in the mixture undergoes heat treatment to ensure that, when all components are combined, the resulting mixture temperature is between 28°C and 40°C. The mixing process can be performed using static mixers, agitators, or similar equipment. Since all components are in liquid form, tank filling can be achieved by natural flow due to height differences, by pumping, or by other mechanical means. This approach significantly reduces labor requirements during carrot handling and improves food safety by minimizing environmental exposure. Additionally, the reduction of carrot particle size via mechanical processing increases the available surface area for fermentation, enhancing microbial and enzymatic activity. As a result, fermentation proceeds more rapidly, and the final taste profile remains consistent across production batches.The main fermentation process takes place under conditions of minimal temperature fluctuation (± 1°C) and lasts for a duration of two to four days. During this period, the pH decreases rapidly, the acidity increases, and the enzymatic hydrolysis of the processed carrots results in their breakdown into fine particles. The fermentation is considered complete when the desired pH, acidity, and taste profile are achieved. At this stage, the fermented §algam juice is harvested from the fermentation vessel through pumping or natural flow. The separation of the liquid from the remaining fermented processed carrot is carried out by filtration, centrifugation, decantation, or a combination thereof. The resulting fermented §algam juice exhibits a standardized pH, acidity, and taste profile, ensuring consistent quality.

[0031] A unique aspect of the present invention is the utilization of the fermented processed carrots generated during fermentation, which possess distinct physicochemical and nutritional properties suitable for various applications. The fermentation process enhances the release of pigments, contributing to its functionality as a natural food coloring agent and food protectant. Additionally, the structural modifications occurring during fermentation, combined with the inherent vitamins and minerals of the processed carrot, further improve its nutritional profile. The high fiber content of the fermented processed carrot provides prebiotic benefits, while the bioactive compounds produced by the selected starter cultures contribute to postbiotic properties. Moreover, the fermentation process enriches the processed carrots with microbial biomass, increasing their protein content. Yeast metabolism during fermentation also generates umami-enhancing compounds, improving the sensory attributes of the final product. The enhanced taste, texture, and nutritional profile of the fermented processed carrot make it a valuable ingredient in various food formulations, including but not limited to sauces, soups, chips, and functional foods.

[0032] Table-1 shows the comparison of sensory properties (Blind taste experiments) of fermented §algam juices produced by traditional method and present invention. Statistical analysis shows that present invention produces fermented §algam juice with similar taste to commercial products. (AB is a comparison of the capital letters sample groups in the same column, and there is no statistical difference between the samples symbolized with the same letters (p>0.05).)

[0033]

[0034] Table-1: Comparison of sensory properties (Blind taste experiments) of fermented §algam juices produced by traditional method and present invention Another important characteristic of the invention is the ability to adjust the concentration of fermented §algam juice by varying the proportion of black or purple carrots used in fermentation. The process allows for the production of concentrated fermented §algam juice by incorporating a carrot content of more than 25% by weight of the total fermentation mixture. This results in a final product with a higher concentration of nutrients and flavor compounds compared to traditionally produced fermented §algam juices. The concentrated fermented §algam juice can either be diluted before bottling or sold directly to consumers, allowing end users to adjust the taste intensity according to personal preference. This approach also offers logistical advantages by reducing transportation and storage costs associated with larger volumes of diluted beverages.

[0035] Through the combination of controlled fermentation conditions, optimized raw material processing, and efficient separation techniques, the present invention provides a scalable and automated method for producing high-quality fermented §algam juice with consistent sensory properties. The improvements introduced by this invention enhance the efficiency of fermented §algam juice production while expanding the potential applications of its byproducts in various food-related industries.

[0036]

[0037] A total of 100 kg of bulgur flour (alternatively ground cereals or ground grains) is mixed with 870 L of hot saltwater containing 0.4% (w / v) salt, wherein the salt is a 1:1 mixture of sodium chloride (NaCl) and potassium chloride (KC1). The mixing is carried out in a tank under controlled conditions. When the temperature of the mixture reaches the desired fermentationtemperature, preferably within the range of 28°C to 37°C, a starter culture is introduced and thoroughly mixed. The starter culture preferably comprises at least one yeast species and at least one lactic acid bacteria species. The mixture is then subjected to fermentation for 36 hours. The exact ratios of the components may be adjusted depending on the desired taste profile and fermentation characteristics. Table-2 shows concentrated fermented §algam juice meeting TS11149 standards prior to 48 hours.

[0038]

[0039] Table-2: Appearance of concentrated fermented §algam juice meeting TS11149 standards prior to 48 hours

[0040] In one embodiment, the salt mixture is 60-unit NaCl and 40-unit KC1.

[0041] In another embodiment salt used does not contain NaCl.

[0042] In yet another embodiment, bulgur flour is fermented without adding any salt.

[0043] In one embodiment, instead of bulgur flour, ground chickpea is used.

[0044] In another embodiment, instead of bulgur flour, ground corn is used.

[0045]

[0046] A total of 2000 kg of black or purple carrots in good condition are washed and cleaned thoroughly. The carrots are subsequently processed by crushing, preferably by shredding, and are forced through a fine screen with an opening size of less than 10 mm. Industrial high speed shredding machines can effectively work in this size range for carrots. The processed carrots are combined with 2000 L of hot saltwater containing 0.4% (w / v) salt, wherein the salt is a 1 : 1 mixture of sodium chloride (NaCl) and potassium chloride (KC1). This mixing is conducted through pipelines under static conditions such that the final mixture reaches a fermentation temperature in the range of 28°C to 40°C.The resultant mixture is combined with the fermented bulgur flour obtained in Example 1, a starter culture containing at least one lactic acid bacteria species, 0.75 kg of arginine, and 5.6 L of an enzyme solution containing 5000 lU / mL of enzymes, preferably pectinase and cellulase. The amount of starter culture is adjusted such that the final mixture contains between 9.0 x io5and 2.5 x 109CFU / mL of microorganisms immediately after mixing. The mixture is subjected to fermentation under controlled conditions at the fermentation temperature for 48 hours. The proportions of ingredients may be modified based on the desired sensory properties of the final product.

[0047] In one embodiment, the amount of processed carrot is adjusted such that it constitutes between 20% and 80% by weight of the total fermentation mixture, with the amount of water or saltwater modified accordingly to maintain the desired consistency and fermentation conditions.

[0048] In another embodiment, the proportions of processed carrot, water or saltwater, enzymes, arginine, fermented bulgur flour, and starter culture are maintained relative to each other, allowing the process to be scaled to any production volume while preserving fermentation characteristics and product consistency.

[0049] In yet another embodiment, the composition of salt, the ratio of different salt components, the amount of salt, arginine, and the enzyme concentrations are adjusted to modify the sensory attributes and taste profile of the final product according to desired specifications.

[0050] In one embodiment, fermentation can continue from the start for 5 days.

[0051] Table-3 shows concentrated fermented §algam juice with varying salt compositions. Concentrated fermented §algam juice with different salt composition reached TS11149 standards prior to 72 hours.

[0052]

[0053] Table-3: Concentrated fermented §algam juice with different salt compositions.Example 3

[0054] Upon completion of the fermentation described in Example 2, the fermented §algam juice is transferred to a decanter for separation of the fermented processed carrots from the liquid. The resulting juice is in a concentrated form, as the amount of carrots used in the process is twice the amount typically used in standard industrial fermented §algam juice production.

[0055] The concentrated fermented §algam juice is subjected to thermal treatment by heating to a temperature of 60°C to 65°C for a duration of 5 minutes. Following heat treatment, the juice is diluted with an equal volume of water, thereby reducing the energy consumption required for heating by 50% compared to conventional processes while eliminating the need for additional cooling steps.

[0056] In one embodiment, the obtained fermented §algam juice is not processed further and can be consumed without pasteurization and food protectants.

[0057] Example 4

[0058] The pasteurized fermented §algam juice obtained in Example 3 is ready for bottling or direct consumption. The fermented processed carrots separated during the decanting process in Example 3 is further processed for additional applications.

[0059] In one embodiment, the obtained fermented processed carrots are subj ected to thermal treatment by heating to a temperature of 60°C to 65°C and is then hot-filled into sterile cans, rendering it ready for consumption as a sauce.

[0060] In an alternative embodiment, the fermented processed carrots are filled into clean cans and subjected to pasteurization while inside the cans. The resulting heat-treated fermented processed carrots are suitable for use as a sauce.

[0061] In yet another embodiment, the fermented processed carrots are directly dried using drying techniques such as drum drying, vacuum drying, freeze drying, or spray drying. The resulting dried fermented processed carrot powder is suitable for use as a natural food coloring agent. In one embodiment, fermented processed carrots are dried and used in soup formulation. In another embodiment, fermented processed carrots are used in biscuit dough.

[0062] In yet another embodiment, fermented processed carrots used in chips formulation.

[0063] In one embodiment, fermented processed carrot is used as postbiotic supplement.Example 5

[0064] A total of 2000 kg of black or purple carrots in good condition are washed and cleaned thoroughly. The carrots are subsequently processed by crushing, preferably by shredding, and are forced through a fine screen with an opening size of less than 10 mm. The processed carrots are combined with 2000 L of hot saltwater containing 0.4% (w / v) salt, wherein the salt is a 1 : 1 mixture of sodium chloride (NaCl) and potassium chloride (KC1). This mixing is conducted through pipelines under static conditions such that the final mixture reaches a fermentation temperature in the range of 28°C to 40°C.

[0065] The resultant mixture is combined with 100kg ground cereal in 870L water, a starter culture at least one lactic acid bacteria species and at least one yeast species, 0.75 kg of arginine, and 5.6 L of an enzyme solution containing 5000 lU / mL of enzymes, preferably pectinase and cellulase. The amount of starter culture is adjusted such that the final mixture contains between 9.0 x io5and 2.5 x 109CFU / mL of microorganisms immediately after mixing. The mixture is subjected to fermentation under controlled conditions at the fermentation temperature for 48 hours. The proportions of ingredients may be modified based on the desired sensory properties of the final product.

[0066] The present invention overcomes microbiological challenges of conventional product by introducing an active starter culture and fermented culture medium during optional controlled bulgur flour or grain / cereal fermentation and main carrot fermentation. This method effectively lowers the pH of the fermentation and ensures that starter cultures dominate any microorganisms from the natural microflora. Furthermore, the high surface area of ground or crushed carrots, along with their improved nutrient availability, accelerates the fermentation process compared to traditional methods, further limiting the growth of undesirable microorganisms.

[0067] Additionally, the processed carrots can optionally be treated with enzymes to enhance nutrient accessibility for the starter cultures, thereby hastening the fermentation process. The shorter fermentation duration, coupled with the dominant presence of starter cultures, ensures more consistent production and safer products. Table-4 shows the analytical comparison of fermented §algam juice produced with present invention and conventionally produced fermented §algam product.

[0068]

[0069] Table-4: Analytical comparison of fermented §algam juice produced with present invention and conventionally produced fermented §algam product.

[0070] The present invention reduces the fermentation time to approximately 2 to 4 days, ensuring a more standardized fermentation profile. This shortened fermentation duration, combined with the elimination of labor-intensive processes and the use of easily cleanable, aceptic process equipment, allows for the use of larger fermentation vessels (e.g., 30 tons or more). This approach stabilizes temperature fluctuations and further contributes to the standardization of the fermentation process.

[0071] Large scale conventional fermented §algam juice producers typically use 1000 tanks in their facilities with each tank having 10000 liters volume. A typical conventional §algam fermentation in given 10000-liter tanks takes 28-32 days depending on the climate (winter or spring). Typically, by cold storing black carrots, producers continue production for 10 months. Since each batch takes around 1 month, with 10 tons volume per tank and 1000 tank, and 20% of the fermentation volume is being waste (solids, mainly sliced black carrots), 80 million liters fermented §algam juice can be produced as theoretical maximum. However, in general, large-scale producers can only produce 50 million to 60 million liters fermented §algam juice due to high losses during storage and production. Additionally, for this scale of conventional production, around 300 workers required.

[0072] On the other hand, with present invention, 30 tons volume 30 tanks with fermentation taking only 3 days, and only around 10% of the fermentation volume is being byproduct (mainly,enzymatically treated processed fermented carrots), 81 million liters fermented §algam can be produced as theoretical maximum. With the present invention, this scale of production only requires 30 to 40 workers and significantly less facility area and significantly less energy usage for climatization. By, employing 35 tanks instead of 30, many of the losses during cold storage of black carrot can be prevented. Additionally, methods presented with this invention produces standardized fermented §algam juice with increased food safety. This prevents loss during production.

[0073] Another main advantage of the present invention during industrial applications is utilization of fermented carrots. During conventional production, carrots are sliced into 4-5 pieces. This step itself limits release of sugars, aroma, antioxidant compounds, other color pigments in black carrots to the fermentation media and increases fermentation time. At the end of the conventional production, sliced black carrots that were originally placed to tanks with bags are removed typically with hooks. This type of fermented carrots contains high salt due to the utilized amount of salt during conventional production making use of fermented carrots impractical. With conventional production, around 50 million kilograms of fermented black carrots are wasted every year. This fermented black carrots either pollute soils as waste or pollute atmosphere as they are burned.

[0074] With present invention, fermented §algam juice can be produced with little to no salt usage. Additionally, use of enzymes and starter culture combined with mechanical processing of black carrots to increase surface area creates tasty and healthy sauce base, very similar taste and sensory characteristics to Luisiana hot sauce, with many special sensory characteristics coming from fermentation with lactic acid bacteria and yeasts and potential benefits as prebiotic due to high fiber content, postbiotic as a fermented product and probiotic when proper microorganism strains are utilized. A typical 250 ml bottled hot sauce or similar sauces priced around 4-15 Euros in stores. By incorporating present invention in all fermented §algam juice production, 50 million kg of fermented carrots are regained to economy with 800 million to 3 billion Euro market-value. Even more valuable byproducts can be produced with prebiotic, postbiotic and potential probiotic benefits of the fermented processed black carrots produced during present invention.References

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Claims

CLAIMS1. A method of manufacturing fermented §algam juice characterized in comprising steps of;i. mixing ground cereal material with water to form a liquid mixture,ii. preparing carrots by washing and mechanically processing them to reduce particle size,iii. combining the liquid mixture with the processed carrots,iv. adding a starter culture of at least one yeast and a lactic acid bacteria, to the mixture and transferring the combined mixture to the fermentation tank by pumping or natural flow,v. subjecting the combined liquid mixture to fermentation between 28°C-40°C, vi. harvesting the fermented §algam juice from the fermentation tank,vii. separating the fermented §algam juice from the remaining fermented processed carrots,wherein the entire process is carried out in water.

2. The method for manufacturing fermented §algam juice according to claim 1, further comprises adding a starter culture of at least one yeast and at least one lactic acid bacteria, to the mixture of ground cereal material of step i.

3. The method for manufacturing fermented §algam juice according to claim 2, wherein the ground cereal selected from the group consisting of bulgur flour, com, barley, chickpea, beans, quinoa, rice, lentil, buckwheat, oat, or rye.

4. The method for manufacturing fermented §algam juice according to claim 1 or 2, further comprises at least one salt selected from the group consisting of NaCl, KC1, CaCb, MgSO4, MgCb, MnSCh, MnCb, MSG, Mg3(PO4)2, NaC3H5O3, C2H3NaO2.

5. The method for manufacturing fermented §algam juice according to claim 1 or 2, further comprises at least one enzyme selected from the group consisting of pectinase, cellulase, glycosidase, hemicellulase, amylase, laccase, naringinase, protease, or tannase is added to facilitate the breakdown of carrot fibers during or after mechanical processing.

6. The method for manufacturing fermented §algam juice according to claim 2, wherein the yeast is selected from the group consisting of Saccharomyces cerevisiae, Pichia kluyveri, Pichia fermentans, and Pichia pastoris.

7. The method for manufacturing fermented §algam juice according to claim 1 or 2, wherein the lactic acid bacteria species is selected from the group consisting of Lactiplantibacillus plantarum, Lactobacillus brevis, Lacticaseibacillus casei, Lactiplantibacillus pentosus, Pediococcus pentosaceus, Lactobacillus rhamnosus, Lactobacillus acidophilus, Leuconostoc mesenteroides, Weissella cibaria, Weissella confusa, Lactiplantibacillus argentoratensis, Pediococcus acidilactici, Lacticaseibacillus paracasei, Lactobacillus reuteri, Levilactobacillus sakei, Weissella koreensis, Lactococcus lactis, Lactobacillus delbrueckii.

8. The method for manufacturing fermented §algam juice according to claim 1 or 2, wherein black or purple carrots are prepared for mechanical processing by pulverization, shredding, grinding, or crushing.

9. The method for manufacturing fermented §algam juice according to claim 8, wherein black or purple carrots are subjected to mechanical processing to reduce size to less than 10 mm.

10. The method for manufacturing fermented §algam juice according to claim 1 or 2, wherein the combining process is performed using static mixers, agitators.

11. The method for manufacturing fermented §algam juice according to claim 1 or 2, further comprises arginine is incorporated into the mixture to enhance the salty and umami flavors of the final product.

12. A fermented product produced by the method according to any one of claims 1 to 11.

13. The fermented product of claim 12, wherein the product is a natural food coloring agent.

14. A fermented product of claim 12, wherein the fermented processed carrots separated in the method are utilized as a sauce after being subjected to a thermal treatment and filled into suitable containers.

15. A fermented product of claim 12, wherein the product is postbiotic supplement.

16. A fermented product of claim 12, wherein the product is prebiotic supplement.

17. A fermented product of claim 12, wherein the product is in concentrated form.

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